Dual element turbine blade

ABSTRACT

A method of manufacturing a turbine blade includes providing a core element having a base portion, a tip portion, and an intermediate portion extending between the base portion and the tip portion. The intermediate portion has a non-uniform cross-section and is a high-strength fiber material. The method also includes surrounding the core element with a shell, the volume between the core element and the shell forming a void.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.13/966,732, filed Aug. 14, 2013, which is incorporated herein byreference in its entirety.

BACKGROUND

Turbine engines are systems that convert energy within a fuel intomechanical energy (e.g., to move an aircraft, to turn an electricalgenerator, etc.). Turbine systems traditionally employ various turbineblades designed to extract energy from a high temperature, high pressuregas produced during a combustion reaction within the turbine engine.Often, turbine blades include a core and shell portion, which rotate atvery high speeds around a central axis.

The high temperature and high speed operating conditions of turbineblades pose various design challenges for the manufacture of turbineblades. Such challenges include creep failure and failure due tofracture, among others. Creep and fracture may ultimately limit theuseable life and the maximum operating temperature of the turbine bladethereby requiring replacement or repair, which may permanently ortemporarily render the turbine engine inoperable. Where turbine bladesare utilized in large-scale power generation facilities or in the jetturbine market, even limited inoperability may have a substantial impacton production, profitability, and revenue.

Turbine blade designers attempt to reduce creep failure and increase themaximum operating temperature using various methods. Foremost, turbineblades may include increased cross-sectional areas to reduce creep.Moreover, turbine blades may include various cooling passagewaysextending outward to a leading edge of the turbine blade to increase themaximum operating temperature of the turbine blade. Such passageways mayfacilitate emission of a fluid (e.g., air) that flows along the outersurface thereby further increasing the maximum operating temperature ofthe turbine blade.

SUMMARY

One embodiment relates to a method of manufacturing a turbine blade. Themethod includes providing a core element having a base portion, a tipportion, and an intermediate portion extending between the base portionand the tip portion. The intermediate portion has a non-uniformcross-section and is a high-strength fiber material. The method alsoincludes surrounding the core element with a shell, a volume between thecore element and the shell forming a void.

Another embodiment relates to a method of manufacturing a turbine blade.The method includes providing a core element having a base portion, atip portion, and an intermediate portion extending between the baseportion and the tip portion. The intermediate portion has a non-uniformcross-section and is a high-strength fiber material. The method alsoincludes surrounding the core element with a shell, a volume between thecore element and the shell forming a void, positioning a structuralelement within the void, and engaging the core element and the shellwith the structural element.

Still another embodiment relates to a method of manufacturing a turbineblade. The method includes providing a core element having a baseportion, a tip portion, and an intermediate portion extending betweenthe base portion and the tip portion. The intermediate portion has anon-uniform cross-section and is a high-strength fiber material. Themethod also includes surrounding the core element with a shell, a volumebetween the core element and the shell forming a void, and extending acooling element through the void, the cooling element configured toincrease a maximum operating temperature at the turbine blade.

The invention is capable of other embodiments and of being carried outin various ways. Alternative exemplary embodiments relate to otherfeatures and combinations of features as may be generally recited in theclaims.

BRIEF DESCRIPTION OF THE DRAWINGS

The skilled artisan will understand that the drawings primarily are forillustrative purposes and are not intended to limit the scope of theinventive subject matter described herein. In the drawings, likereference characters generally refer to like features (e.g.,functionally similar and/or structurally similar elements).

FIG. 1 is a schematic view of a turbine engine, according to anexemplary embodiment.

FIG. 2 is a schematic view of a turbine blade assembly, according to anexemplary embodiment.

FIG. 3 is an elevation view of a turbine blade having a core element anda shell member, according to an exemplary embodiment.

FIG. 4 is a cross-sectional view of a turbine blade having a taperedcore element, according to an exemplary embodiment.

FIG. 5 is a cross-sectional view of a turbine blade having a taperedcore element and a support member, according to an exemplary embodiment.

FIG. 6 is a cross-sectional view of a turbine blade having a taperedcore element and a support member, according to an exemplary embodiment.

FIG. 7 is a cross-sectional view of a turbine blade having a taperedcore element and a support member, according to an exemplary embodiment.

FIG. 8 is a cross-sectional view of a turbine blade having a taperedcore element and a support member, according to an exemplary embodiment.

FIG. 9 is a cross-sectional view of a turbine blade having a taperedcore element and a support member, according to an exemplary embodiment.

FIG. 10 is a cross-sectional view of a turbine blade having a taperedcore element and a support member, according to an exemplary embodiment.

FIG. 11 is a cross-sectional view of a turbine blade having a taperedcore element and a thermal regulation system, according to an exemplaryembodiment.

FIG. 12 is a cross-sectional view of a turbine blade having a taperedcore element and a thermal regulation system, according to an exemplaryembodiment.

FIG. 13 is a cross-sectional view of a turbine blade having a taperedcore element and a thermal regulation system, according to an exemplaryembodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplaryembodiments in detail, it should be understood that the application isnot limited to the details or methodology set forth in the descriptionor illustrated in the figures. It should also be understood that theterminology is for the purpose of description only and should not beregarded as limiting.

Dual element turbine blades are intended to provide various advantagesover single element turbine blade designs. Such dual element turbineblades may be used in various turbine applications (e.g., a gas turbine,a wind turbine, a steam turbine, an oceanic turbine system, etc.).Specifically, the turbine blade includes a core element and a shellportion. The core element of the turbine blade is designed to carry thestructural loads imparted on the turbine blade thereby reducing thestructural loading that must be carried by the shell. Rather than carrystructural loading, the shell performs aerodynamic functions and shieldsthe core from exposure to high-temperature gasses. This configurationallows the core element and the shell portion to be designed withdifferent materials. According to an exemplary embodiment, the coreelement is high-strength and operates at a relatively low temperature(e.g., 600 degrees Celsius) and the shell portion is lower-strength andoperates at a relatively high temperature (e.g., 1,000 degrees Celsius).The core element may be manufactured from a material that is differentfrom the shell portion. By way of example, the core element may bemanufactured from a material optimized for high strength at lowoperating temperatures (e.g., a high-strength fiber material) and theshell portion may be manufactured from a material optimized for ahighest maximum operating temperature. In some embodiments, the dualelement turbine blade may operate at a greater temperature thantraditional turbine blades thereby improving efficiency of the turbineengine. Such a non-structural shell portion may also have a reducedcross-sectional area or density. In some embodiments, the core elementis coupled to the shell portion with structural elements. In otherembodiments, cooling elements extend through a void between the coreelement and the shell portion. Such cooling elements may transfer energyfrom the shell portion to increase the maximum operating temperature ofthe turbine blade.

Referring first to the exemplary embodiment shown in FIG. 1, a turbineengine, shown as turbine engine 10, includes various sections. As shownin FIG. 1, turbine engine 10 includes a primary housing, shown as casing12. An airflow, shown as airflow 14, travels through a front portion ofturbine engine 10. As shown in FIG. 1, airflow 14 travels into the frontportion of turbine engine 10 and through casing 12.

Referring still to the exemplary embodiment shown in FIG. 1, turbineengine 10 includes a low pressure compressor, shown as low pressureportion 16 and a high pressure compressor, shown as high pressureportion 18. In some embodiments, airflow 14 entering casing 12 ispressurized within low pressure portion 16 and further pressurized inhigh pressure portion 18. As shown in FIG. 1, turbine engine 10 alsoincludes a combustion chamber, shown as chamber 20. High pressure airflow enters chamber 20 and may be thereafter combined with fuel prior tocombustion. After the fuel-air mixture within chamber 20 combusts,airflow travels through a low pressure turbine, shown as exhaust section22.

In some embodiments, various turbine blades, shown as blades 13, aredisposed within low pressure portion 16, high pressure portion 18, andexhaust section 22. In some embodiments, blades 13 within each portionof turbine engine 10 are designed for the operating conditions withinone of the low pressure portion 16, high pressure portion 18, andexhaust section 22. In some embodiments, blades 13 within exhaustsection 22 experience higher operating temperatures and stresses thanthe blades 13 of low pressure portion 16 and high pressure portion 18.Specifically, blades 13 within exhaust section 22 are exposed to hightemperatures due to the combustion of fuel and air within chamber 20.Such high temperatures pose additional design challenges for themanufacture of blades 13. While FIG. 1 shows an exemplary turbineengine, it should be understood that other types of turbine engines orturbine engines having more or fewer sections or numbers of blades mayalso utilize turbine blades that are exposed to adverse operatingconditions.

Referring next to the exemplary embodiment shown in FIG. 2, a turbineblade assembly, shown as assembly 30, includes a plurality of turbinefin elements, shown as turbine blades 32. According to an exemplaryembodiment, assembly 30 may be placed within one of the various sectionswithin a turbine engine. As shown in FIG. 2, turbine blade 32 extendsradially outward from a rotor hub, shown as hub 34. According to anexemplary embodiment, turbine blade 32 is coupled to hub 34 at aninterface, shown as root 36. In some embodiments, turbine blades 32 maybe shaped (e.g., with a leading edge, a center portion, and a trailingedge) to facilitate the extraction of energy from the exhaust gassesflowing through the turbine engine. It should be understood thatassembly 30 may include a plurality of turbine blades 32 disposedradially around hub 34.

As shown in FIG. 2, assembly 30 is configured to rotate at an angularvelocity, shown as w, about a centerline of hub 34. As assembly 30rotates, turbine blades 32 are placed in tension due to centrifugalforces acting on turbine blades 32. In addition, the turbine blades 32experience reaction forces associated with the combustion gasses thatare relatively small compared to the centrifugal forces. Where the massdistribution is constant along the length of turbine blade 32, the forceat root 36 is directly related to the density of the material, thecross-sectional area, the square of the angular velocity, and thesquared length of turbine blade 32. Such a constant mass distributionmay occur where, among other potential situations, the density and crosssectional area of the turbine blade 32 are constant along the length ofturbine blade 32.

According to an alternative embodiment, the cross-sectional area ofturbine blade 32 is not uniform along the length of turbine blade 32. Byway of an extreme example, a turbine blade having a total masspositioned at its length from the axis of rotation will produce agreater centripetal force than a turbine blade having a uniform shape ora turbine blade having a total mass positioned more near to the axis ofrotation. Such a distribution of mass along the length of the turbineblade may impact various characteristics of the turbine blade (e.g.,likelihood of creep or fatigue failure, etc.). According to an exemplaryembodiment, turbine blade 32 includes components (e.g., core element,shell portion, etc.) manufactured from materials having a preferredtensile strength to density ratio. Such a turbine blade 32 balancesdensity with strength to carry tensile loading without magnifying theforces due to the rotating mass of turbine blade 32.

Referring next to FIG. 3, a turbine blade 40 configured to operatewithin a turbine engine is shown, according to an exemplary embodiment.It should be understood that turbine blade 40 may be positioned within aturbine engine in a manner as discussed above or in still anotherconfiguration. In some embodiments, turbine blade 40 is configured toextract energy from an airflow.

As shown in FIG. 3, turbine blade 40 includes a base portion, shown asbase member 50. According to an exemplary embodiment, turbine blade 40includes a core element (e.g., structural element, shaft, pillar, etc.),shown as spine member 60. As shown in FIG. 3, spine member 60 is atleast partially surrounded by a shell, shown as shell 70. As shown inFIG. 3, shell 70 extends along the length of spine member 60. Accordingto an exemplary embodiment, spine member 60 is coupled to shell 70 withan end cap. Those skilled in the art will appreciate that the end capmay be coupled to the ends of spine member 60 and shell 70 and may applycompressive forces to the shell. Such applied compressive forces may begenerated by placing the spine member 60 in tension. It should beunderstood that compressive forces applied to shell 70 increases thetensile loading that shell 70 may experience prior to failure.

According to an exemplary embodiment, base member 50 couples turbineblade 40 to the various other components of a turbine engine (e.g., thehub, etc.). In other embodiments, turbine blade 40 may not include abase member 50 and may be otherwise coupled within a turbine assembly(e.g., a gas turbine, etc.). As shown in FIG. 3, base member 50 includesan upper surface, shown as interface surface 52. In some embodiments,interface surface 52 extends as a flat plane. In other embodiments,interface surface 52 may have another shape configured to engage atleast one of spine member 60 and shell 70.

Referring still to the exemplary embodiment shown in FIG. 3, base member50 includes a retaining portion, shown as locking portion 54. In someembodiments, turbine blade 40 may rotate at high speeds within a turbineengine. In those embodiments, centripetal forces may overcome othertypes of fastening systems (e.g., a bolted connection, a weldedconnection, etc.). However, a turbine blade 40 having a locking portion54 may engage (i.e. interface with) a mating aperture (i.e. slot,channel, etc.) within the hub.

According to the exemplary embodiment shown in FIG. 3, spine member 60has a teardrop cross-sectional shape that tapers as it extends radiallyoutward from base member 50. In other embodiments, spine member 60 has auniform cross-section. Spine member 60 may alternatively have anothershape (e.g., a rectangle, a “T” shape, various curved shapes, a shapecreated from various subcomponents, etc.). According to an exemplaryembodiment, spine member 60 is tubular and includes at least onesidewall extending along the length of spine member 60 (e.g., to providea tubular structure having improved strength in bending, etc.). Inembodiments where spine member 60 is tubular, the sidewall may define aninner void (e.g., to allow a fluid to flow through spine member 60,etc.).

According to an exemplary embodiment, spine member 60 includes endportions configured to interface with base member 50. Such end portionsmay have different diameters, different shapes, differentcross-sectional areas, or still other different features. In someembodiments, spine member 60 may be flexible (e.g., have a Young'smodulus that is lower than the Young's modulus of at least one of basemember 50 and shell 70). In other embodiments, spine member 60 may be arigid structure.

According to an exemplary embodiment, spine member 60 is coupled (e.g.,integrally formed, welded, adhesively secured, bolted, etc.) to basemember 50. As shown in FIG. 3, spine member 60 structurally supportsturbine blade 40. Loading from turbine blade 40 is transferred throughbase member 50 and into the hub or central shaft of the turbine engine.Such loading may be due to centripetal forces and relatively smallbending forces due to the force of an airflow flowing across turbineblade 40.

Referring still to the exemplary embodiment shown in FIG. 3, spinemember 60 may comprise various known materials. According to anexemplary embodiment, spine member 60 is a metal. According to analternative embodiment, spine member 60 is manufactured from ahigh-strength fiber-based material (e.g., carbon fibers, polydioxanoneor other polymer fibers, boron nitride fibers, ceramic fibers, nanotubefibers, etc.). According to still another alternative embodiment, spinemember 60 includes fibers disposed within a matrix material (i.e. acomposite). According to an exemplary embodiment, the fibers arearranged in at least one of a twisted, woven, and spun bundle. Accordingto an alternative embodiment, the fibers may be otherwise disposedalongside one another.

Referring still to the exemplary embodiment shown in FIG. 3, shell 70extends radially outward from base member 50. As shown in FIG. 3, shell70 is fixed (e.g. integrally formed with, welded, adhesively secured,bolted, etc.) to base member 50. In other embodiments, shell 70 mayotherwise interface with base member 50 (e.g., contact, slidably coupledwith, rotatably coupled with, etc.). In still other embodiments, shell70 may be isolated from base member 50.

As shown in FIG. 3, shell 70 at least partially surrounds (e.g., extends360 degrees around the perimeter of) spine member 60. According to anexemplary embodiment, shell 70 has an airfoil shape designed to engagean airflow moving past turbine blade 40. In some embodiments, shell 70includes a cross-section having a circularly shaped first end and apointed second end. The circular first end may have sidewalls extendinginto a crescent shaped intermediate portion and toward the pointedsecond end. Such a configuration of walls may facilitate the ability ofshell 70 to engage the airflow. In other embodiments, shell 70 may haveanother cross-sectional shape (e.g., elliptical, circular, etc.).

According to an exemplary embodiment, shell 70 comprises a material thatis different from that of spine member 60. The material of shell 70 maybe designed for high-temperature conditions. Shell 70 may comprisevarious materials (e.g., a metal, a non-metal, a metal-ceramiccomposite, a polymer, carbon fibers, polydioxanone or other polymerfibers, boron nitride fibers, ceramic fibers, nanotube fibers, etc.).

Referring still to the exemplary embodiment shown in FIG. 3, shell 70 isa tubular (i.e. hollow, empty, etc.) structure at least partiallysurrounding spine member 60. Such a shell 70 may include an innersurface and an outer surface separated by a sidewall. As discussedabove, the outer surface of shell 70 may be subjected tohigh-temperature airflow from the exhaust gasses from a gas turbineengine. According to an exemplary embodiment, a void is formed betweenthe inner surface of shell 70 and the outermost surface of spine member60. In some embodiments, a void may be formed between an inner surfaceof shell 70, which may itself have a porous structure, and the meansurface of a porous spine member 60 (e.g., a nanotube product comprisinga lattice structure).

According to an exemplary embodiment, shell 70 has a uniformcross-section (i.e. a cross-section that does not vary in shape orthickness along the length of shell 70). Such a shell 70 may have aconstant wall thickness (e.g., 0.25 inches, 0.5 inches, etc.). In otherembodiments, shell 70 has a non-uniform cross-section. Such a shell 70may have a wall thickness or cross-sectional shape that varies along thelength of shell 70 (e.g., the wall thickness may decrease along thelength of shell 70).

Referring next to the exemplary embodiment of FIG. 4, a sectional viewof turbine blade 40 is shown. As shown in FIG. 4, turbine blade 40includes a shell 70 at least partially surrounding spine member 60.According to an exemplary embodiment, spine member 60 extendsorthogonally from interface surface 52 of base member 50.

According to an exemplary embodiment, spine member 60 includes anon-uniform cross-section. As shown in FIG. 4, spine member 60 includesa lower portion (i.e. base portion, coupling portion, etc.) shown asroot end 62 and an upper portion end (i.e. tip portion, opposingportion, etc.) shown as cap end 64. In some embodiments, spine member 60includes a central region (i.e. intermediate portion, etc.), shown asbody portion 66. Body portion 66 is defined as the region of spinemember 60 between root end 62 and cap end 64.

As shown in FIG. 4, spine member 60 has a tapered shape extending frombase member 50. Such a tapered spine member 60 may have a teardropshaped cross-section. According to an exemplary embodiment, cap end 64of spine member 60 includes a smaller cross-sectional area than root end62 of spine member 60. In other embodiments, spine member 60 isotherwise shaped but tapers (i.e. narrows, decreases, decreases in atleast one of cross-sectional area and density of the material) betweenroot end 62 and cap end 64.

According to an alternative embodiment, a turbine blade includes aplurality of core elements (i.e. at least two). Such a plurality of coreelements may be arranged in various configurations (e.g., parallel toone another, angularly offset relative to one another, one within theother, etc.). In some embodiments, the plurality of core elements maynot extend along straight lines (e.g., the plurality of core elementsmay be arranged in a woven configuration, a non-woven configuration, acurved configuration, or in still another configuration). The pluralityof core elements may carry structural loading of a turbine blade. Such aplurality of core elements may be oriented to carry rotational loadingor loading due to other forces (e.g., bending forces, etc.).

Referring next to the exemplary embodiment shown in FIGS. 5-6, a turbinefin element, shown as turbine blade 80 includes a base portion, shown asbase member 90. According to an exemplary embodiment, turbine blade 80includes a core element, shown as spine member 100. As shown in FIGS.5-6, spine member 100 includes a non-uniform cross-section. In someembodiments, spine member 100 is at least partially surrounded by acasing, shown as shell 110. A portion of shell 110 is hidden in FIG. 5to expose spine member 100. As shown in FIG. 5, shell 110 extends alongthe length of spine member 100. According to an exemplary embodiment,spine member 100 is coupled to shell 110 with an end cap.

According to the exemplary embodiment shown in the cross-sectional viewof FIG. 5 and the top view of FIG. 6, shell 110 may comprise a hollowstructure. As shown in FIGS. 5-6, shell 110 includes an inner surfaceand an outer surface separated by a sidewall. According to the exemplaryembodiment shown in FIGS. 5-6, spine member 100 includes an outersurface, and a void space, shown as void 120, is formed between theouter surface of spine member 100 and the inner surface of shell 110.

Referring still to the exemplary embodiments shown in FIGS. 5-6, turbineblade 80 includes a structural element, shown as support 130, extendingthrough void 120. In some embodiments, support 130 is configured tocouple (e.g., attach, fix, adjoin, etc.) spine member 100 and shell 110.As shown in FIG. 5, support 130 has a circular cross-section. In otherembodiments, support 130 is otherwise shaped. While turbine blade 80 isshown in FIGS. 5-6 to include a single support 130, turbine blade 80 mayinclude a plurality of supports 130, according to various alternativeembodiments. Such supports may be evenly distributed around spine member100 or may be otherwise positioned within void 120 (e.g., positionedalong a single side of spine member 100, randomly distributed, etc.).According to an alternative embodiment, support 130 may include across-section having a rectangular or hexagonal shape. According tostill other alternative embodiments, support 130 may have a tubularshape (e.g., to provide enhanced resistance to bending stresses). Insome embodiments, support 130 is flexible (e.g., a higher young'smodulus than spine member 100). In other embodiments, support 130 is arigid structure. In some embodiments, support 130 may be configured toapply compressive forces on shell 110. In other embodiments, support 130is configured to transfer loading applied to shell 110 to spine member100.

According to an exemplary embodiment, support 130 is configured tostructurally couple spine member 100 and shell 110. In some embodiments,an interface is formed at the boundary between support 130 with spinemember 100 and shell 110. Such an interface may comprise an adhesivematerial disposed between support 130 and at least one of spine member100 and shell 110. In other embodiments, the interface may be formed atthe welded interface, the cross-linked boundary, or another jointbetween support 130 and at last one of spine member 100 and shell 110.According to an exemplary embodiment, the interface portion extendsaround the periphery of support 130 (e.g., to more completely securesupport 130 to at least one of spine member 100 and shell 110).

As shown in FIGS. 5-6, support 130 is coupled to a central region (i.e.intermediate portion, etc.) of spine member 100. In some embodiments,support 130 may be coupled to another portion of spine member 100 (e.g.,a portion of spine member 100 proximate base member 90, etc.). Accordingto an exemplary embodiment, support 130 extends laterally away from acenterline of spine member 100 along an extension axis.

In some embodiments, an offset angle, shown as offset angle θ, isdefined between the centerline of spine member 100 and the extensionaxis of support 130. In other embodiments, offset angle θ may be definedbetween the outer surface of spine member 100 (e.g., the surface ofspine member 100 exposed to void 120) and the extension axis of support130. As shown in FIG. 5, the offset angle θ is approximately 90 degrees.In other embodiments, the offset angle θ may be less than 90 degrees. Instill other embodiments, at least one of support 130 and spine member100 do not extend in a linear direction (i.e. support 130 or spinemember 100 may have a curved shape). Such a non-linear support 130 orspine member 100 may be otherwise positioned within void 120.

Referring next to the embodiment shown in FIG. 7, turbine blade 80includes shell 110 coupled to spine member 100 with a plurality ofsupports 130. According to an exemplary embodiment, spine member 100includes a plurality of individual high-strength fibers (e.g., carbonfibers, polydioxanone or other polymer fibers, boron nitride fibers,nanotube fibers, etc.). As shown in FIG. 7, a portion of suchhigh-strength fibers peel off of spine member 100 and engage shell 110to form the plurality of supports 130. According to the exemplaryembodiment shown in FIG. 7, the supports 130 are arcuate and may eachhave a different shape. The supports 130 may be shaped with a constantradius (e.g., as part of a circle) or with a radius that changes alongthe length of supports 130 (e.g., as part of an ellipse). The supports130 may alternatively have a uniform shape. In other embodiments, thehigh-strength fibers otherwise extend laterally outward from acenterline of spine member 100 to form supports 130 (e.g.,perpendicularly, at a constant angle, etc.). According to an alternativeembodiment, supports 130 are high-strength fibers coupled (e.g.,molecularly cross-linked, adhesively secured, etc.) to a non-fibrousspine member 100 (e.g., manufactured from a solid material). Supports130 couple spine member 100 and shell 110. According to an exemplaryembodiment, supports 130 are initially loaded in tension to generatecompressive stresses within shell 110.

Referring next to the alternative embodiment shown in FIG. 8, turbineblade 80 may experience loading due to air flowing through a turbineengine. Such an airflow may apply a force, shown as aerodynamic load140, on shell 110. Such forces on shell 110 may be relatively small incomparison to the centrifugal forces generated due to the rotation ofturbine blade 80. In embodiments where shell 110 is coupled to basemember 90, a portion of aerodynamic load 140 may be transferred to basemember 90 through an interface (e.g., bolted connection, welded portion,etc.). According to an alternative embodiment, shell 110 is isolatedfrom base member 90. Such a shell 110 may transfer the entirety ofaerodynamic load 140 to spine member 100 through at least one support130. While shown in FIG. 8 as having a single support 130, it should beunderstood that turbine blade 80 may include a plurality of supports 130to reduce the forces imparted on a single support 130. Such supports 130may be arranged within a line (e.g., extending within a common planefrom spine member 100), may be arranged within several lines (e.g.,extending within several planes from spine member 100), or may beotherwise arranged (e.g., randomly, etc.). Turbine blade 80 mayalternatively include supports 130 configured to transfer aerodynamicload 140 and supports 130 to apply compressive loading to shell 110.

As shown in FIG. 8, turbine blade 80 includes a support 130 positionedalong the direction of aerodynamic load 140. According to an exemplaryembodiment, aerodynamic load 140 interacts with a first side, shown asintake side 112, of shell 110. As shown in FIG. 8, shell 110 alsoincludes a second side, shown as exhaust side 114. While this discussionillustrates an exemplary embodiment of shell 110 configured to interactwith an aerodynamic load 140 along an intake side 112, it should beunderstood that other turbine fins may experience other load cases ormay be otherwise shaped. Supports 130 may be positioned within suchturbine fins to carry the loading.

Referring still to the exemplary embodiment shown in FIG. 8, support 130of turbine blade 80 is aligned with the direction of aerodynamic load140. As shown in FIG. 8, support 130 is coupled to spine member 100 andexhaust side 114 of shell 110. Such a support 130 may experience onlytensile stresses and may transfer aerodynamic load 140 from shell 110 tospine member 100. In some embodiments, support 130 may be manufacturedfrom a flexible material or a material designed to withstand largetensile stresses. According to an exemplary embodiment, support 130 ismanufactured from a fiber material (e.g., carbon fiber, a nanotube,boron nitride fiber, etc.). Those skilled in the art will understandthat such fibrous materials may have a large tensile strength. Accordingto an exemplary embodiment, turbine blade 80 having support 130 coupledto exhaust side 114 of shell 110 and placed in tension is designed toemploy the large tensile strength of support 130.

Referring next to the alternative embodiment shown in FIG. 9, support130 of turbine blade 80 is aligned with the direction of aerodynamicload 140. As discussed above, support 130 may transfer aerodynamic load140 from shell 110 to spine member 100. As shown in FIG. 9, support 130is coupled to spine member 100 and to intake side 112 of shell 110.Where aerodynamic load 140 acts on shell 110 in the direction indicatedin FIG. 9 (i.e. toward intake side 112 of shell 110), support 130 may beplaced in compression and experience compressive forces.

In some embodiments, support 130 may have a shape configured tofacilitate the transmission of aerodynamic load 140 from shell 110 tospine member 100. By way of example, support 130 may have a large areamoment of inertia (e.g., a tubular structure) to prevent buckling. Asshown in FIG. 9, support 130 has a circular cross-section. In otherembodiments, support 130 has another shape. Regardless of thecross-sectional shape, support 130 may be manufactured from a materialhaving a large compressive strength (i.e. a material capable ofwithstanding large compressive loading without buckling). Under theloading conditions shown in FIG. 9, support 130 may experience onlycompressive loading. Such a load case may allow for the selection ofmaterials particularly suited for compressive loading and may allow forthe use of materials that may exhibit lower tensile strengths (e.g., aceramic material, other brittle materials, etc.).

Referring next to the exemplary embodiment shown in FIG. 10, turbineblade 80 includes a first structural member, shown as support 132, and asecond structural support, shown as support 134. As shown in FIG. 10,support 132 is coupled to intake side 112 of shell 110 and support 134is coupled to exhaust side 114 of shell 110. According to an exemplaryembodiment, support 132 and support 134 are each also coupled to spinemember 100. In some embodiments, support 132 and support 134 may bemanufactured from the same material. Where turbine blade 80 experiencesaerodynamic load 140, a material for support 132 and support 134 mayhave large compressive and tensile strengths (e.g., a metal, etc.).

In other embodiments support 132 may be manufactured from a firstmaterial (e.g., a material having a large compressive strength) andsupport 134 may be manufactured from a second material (e.g., a materialhaving a large tensile strength). Such a configuration may promoteefficient loading of spine member 100 through the selection of materialsspecifically suited for loading in a particular portion of turbine blade80. According to an exemplary embodiment, the selection of locationspecific material may reduce the cross-sectional area of the supports130 within void 120 of turbine blade 80. Such a reduction incross-sectional area may reduce the mass of turbine blade 80 that ispositioned away from the base portion thereby reducing the root forcesand mass moment of inertia, as discussed above.

According to various other alternative embodiments, a turbine blade mayinclude a plurality of support members. Such support members may extendlaterally between the core element and the shell, may extend at an anglerelative to the core element, or may otherwise couple the core elementto the shell. The support members may couple the core element to theshell in various locations. Such locations may include at least one ofnear the root of the turbine blade, near the tip or cap end of theturbine blade, or along a central region of the turbine blade. Thesupport members may extend along a linear direction or may be curved(e.g., to differentially distribute an aerodynamic load relative tolinear support members). In other embodiments, a turbine blade mayinclude support members extending between portions of the shell (e.g.,to prevent compression of the tubular shell structure). In still otherembodiments, various support members may be coupled to other supportmembers to form a network or matrix support unit.

According to still another alternative embodiment, the shell may beotherwise coupled to the core element. By way of example, the voidformed between the inner surface of the shell and the outer surface ofthe core element may be at least partially filled with a material.According to an exemplary embodiment, filling the void with a materialcouples the entire length of the core element to the shell. In someembodiments, the void may be filled with materials having a lowerdensity at the tip of the turbine blade. Such a configuration may reducethe mass moment of inertia for the turbine blade by reducing the mass ofthe turbine blade radially offset from the turbine blade root. Accordingto an exemplary embodiment, the void is filled with a metal. Accordingto various alternative embodiments, the void may be filled with asynthetic, a composite, a plurality of nanotube elements disposed withina binder, a foam material, or filled with another material.

Referring next to FIGS. 11-13, turbine blades having a thermalregulation system are shown, according to various alternativeembodiments. As discussed above, various turbine blades may be locatedwithin a gas turbine engine downstream of a combustion chamber. Due tothe release of thermal energy during combustion, such turbine blades maybe exposed to a high temperature airflow. A turbine blade having athermal regulation system may have a greater maximum operatingtemperature relative to traditional turbine blades thereby increasingthe efficiency of the turbine engine.

According to the exemplary embodiment shown in FIG. 11, a turbine blade200 includes a thermal regulation system originating from a baseportion, shown as base portion 210. In some embodiments, base portion210 includes a planar surface, shown as surface 212. According to anexemplary embodiment, turbine blade 200 includes a core element, shownas spine member 220 and a shell, shown as shell 230. As shown in FIG.11, spine member 220 and shell 230 extend orthogonally from surface 212.In some embodiments, a void, shown as void 235, is defined by the volumebetween an inner surface of shell 230 and an outer surface of spinemember 220.

Referring still to FIG. 11, base portion 210 defines a plurality ofapertures, shown as base cooling apertures 214. According to anexemplary embodiment, turbine blade 200 includes a plurality of coolingelements, shown as cooling elements 240. As shown in FIG. 11, coolingelements 240 are positioned within void 235 between shell 230 and spinemember 220. Cooling elements 240 are configured to increase the maximumoperating temperature of shell 230. In some embodiments, coolingelements 240 are tubular members configured to also apply forces onshell 230 (e.g., to produce compressive stresses). According to anexemplary embodiment, each of the plurality of cooling elements 240includes a first end, shown as root end 242 and a second end, shown asdistal end 244. In some embodiments, root end 242 is coupled to baseportion 210 of turbine blade 200. As shown in FIG. 11, shell 230 definesa plurality of apertures, shown as shell cooling apertures 232. In someembodiments, cooling elements 240 couple base cooling apertures 214 toshell cooling apertures 232. By way of example, distal ends 244 ofcooling elements 240 may be coupled to shell 230 and positioned overshell cooling apertures 232. Root ends 242 of cooling elements 240 maybe similarly coupled to base portion 210 and positioned over basecooling apertures 214. In other embodiments, cooling elements 240 may becoupled to a common manifold that is also coupled to a base coolingaperture 214.

According to the alternative embodiment shown in FIG. 12, a turbineblade 300 includes a thermal regulation system originating from a baseportion, shown as base portion 310. In some embodiments, base portion310 includes a planar surface, shown as surface 312. According to anexemplary embodiment, turbine blade 300 includes a core element, shownas spine member 320 and a shell, shown as shell 330. As shown in FIG.12, spine member 320 and shell 330 extend orthogonally from surface 312.In some embodiments, a void, shown as void 335, is defined by the volumebetween an inner surface of shell 330 and an outer surface of spinemember 320.

Referring still to FIG. 12, base portion 310 defines an aperture, shownas base cooling aperture 314. According to an exemplary embodiment,spine member 320 is a tubular structure and includes at least onesidewall, shown as sidewall 322, that defines an inner void space, shownas flow path 324. As shown in FIG. 11, a root end of spine member 320 iscoupled to base portion 310 and disposed over base cooling aperture 314.

According to an exemplary embodiment, turbine blade 300 includes aplurality of cooling elements, shown as cooling elements 340. As shownin FIG. 11, cooling elements 340 are positioned within void 335 andcoupled to spine member 320 and shell 330. As shown in FIG. 12, shell330 defines a plurality of apertures, shown as shell apertures 332, andspine member 320 defines a plurality of apertures, shown as spineapertures 326. According to an exemplary embodiment, cooling elements340 are coupled to both shell 330 and spine member 320 and include endsdisposed over shell apertures 332 and spine apertures 326.

In some embodiments, a fluid (e.g., air, another gas, a liquid, etc.) isflowed through base cooling aperture 314 (e.g., from within an apertureof a hub of the turbine blade assembly). The fluid may have atemperature that is controlled (i.e. regulated, monitored, cooled, etc.)to increase the maximum operating temperature of turbine blade 300. Insome embodiments, the temperature of the fluid is selected (i.e. thefluid is provided at a specified temperature) to increase the maximumoperating temperature of turbine blade 300 while preventing thermalstresses from fracturing one of the various elements of turbine blade300 (e.g., due to a large disparity in temperature between shell 330 orspine member 320 and the fluid).

According to the exemplary embodiment shown in FIG. 12, the fluid may beflowed through base cooling aperture 314 and into flow path 324 withinspine member 320. Thereafter, the fluid may flow through spine apertures326, into cooling elements 340, and exit through shell apertures 332.According to an exemplary embodiment, the fluid forms a protective layerof air across an outer surface of shell 330. Such a protective layer mayshield the outer surface of shell 330 and allow turbine blade 300 tofunction at a higher operating temperature. While a fluid flow throughthe cooling elements 340 of turbine blade 300 has been explicitlydiscussed, it should be understood that a fluid may be similarly routedthrough cooling elements 240 of turbine blade 200 as part of a thermalregulation system.

According to an alternative embodiment, spine member 320 and shell 330define spine apertures 326 and shell apertures 332, respectively, andturbine blade 300 does not include cooling elements 340. The fluid maybe flowed through base cooling aperture 314, into void 335, and out fromshell 330 through shell apertures 332. Such an arrangement does notrequire cooling elements extending between shell apertures 332 and spineapertures 326. In some embodiments, the fluid may fill void 335 beforeflowing outward through shell apertures 332 (e.g., thereby absorbingthermal energy from shell 330 prior to flowing through shell apertures332). In other embodiments, the fluid is not provided to at least aportion of void 335 (e.g., the fluid is flowed at high pressure throughspine apertures 326 and corresponding shell apertures 332).

Referring next to the exemplary embodiment shown in FIG. 13, a turbineblade 400 includes a thermal regulation system originating from a baseportion, shown as base portion 410. In some embodiments, base portion410 includes a planar surface, shown as surface 412. According to anexemplary embodiment, turbine blade 400 includes a core element, shownas spine member 420 and a shell, shown as shell 430. As shown in FIG.12, spine member 420 and shell 430 extend orthogonally from surface 412.In some embodiments, a void, shown as void 435, is defined by the volumebetween an inner surface of shell 430 and an outer surface of spinemember 420.

According to the exemplary embodiment shown in FIG. 13, turbine blade400 includes a plurality of cooling elements, shown as heat sinks 440.As shown in FIG. 12, heat sinks 440 are coupled to shell 430 of turbineblade 400. In other embodiments, heat sinks 440 may be coupled to spinemember 420 and shell 430 or only to spine member 420. Where heat sinks440 include a first end and a second end both coupled to at least one ofspine member 420 and shell 430, heat sinks 440 may be placed under apre-load tension. In embodiments where heat sinks 440 have a free endextending into void 435, a material may be disposed on the free end tolimit degradation heat sinks 440.

According to an exemplary embodiment, heat sinks 440 comprise flexiblefibers (e.g., carbon fibers, carbon nanotubes, boron nitride nanotubes,metallic fibers, etc.) that transfer heat from shell 430. In someembodiments, heat sinks 440 comprise nanotubes having chiralitiesdesigned to facilitate the transfer of thermal energy. According to analternative embodiment, heat sinks 440 may be rigid structures or mayhave another shape (e.g., a fin shape, etc.).

As shown in FIG. 13, base portion 410 defines a plurality of apertures,shown as base aperture 414 and base aperture 416, that interface withvoid 435. According to an exemplary embodiment, a fluid may be flowedthrough base aperture 414 and base aperture 416 and into void 435 whereit absorbs thermal energy from heat sinks 440. In some embodiments, thefluid thereafter flows through apertures defined within shell 430. Thefluid may form a protective layer across an outer surface of shell 430to shield shell 430 from high temperature gasses within a turbineengine. Such an arrangement of heat sinks 440 coupled to shell 430 mayprovide generalized cooling to shell 430 as the fluid absorbs energyfrom heat sinks 440 while providing localized cooling (e.g., as thefluid flows through apertures within shell 430) and a protective outerlayer. In other embodiments, at least a portion of the fluid is directedback into base portion 410. Such a configuration of a thermal regulationsystem may allow for the fluid to be routed within void 435 and thenreprocessed (e.g., reduce the temperature and again flow the fluidthrough void 435).

It is important to note that the construction and arrangement of theelements of the systems and methods as shown in the exemplaryembodiments are illustrative only. Although only a few embodiments ofthe present disclosure have been described in detail, those skilled inthe art who review this disclosure will readily appreciate that manymodifications are possible (e.g., variations in sizes, dimensions,structures, shapes and proportions of the various elements, values ofparameters, mounting arrangements, use of materials, colors,orientations, etc.) without materially departing from the novelteachings and advantages of the subject matter recited. For example,elements shown as integrally formed may be constructed of multiple partsor elements. It should be noted that the elements and/or assemblies ofthe enclosure may be constructed from any of a wide variety of materialsthat provide sufficient strength or durability, in any of a wide varietyof colors, textures, and combinations. Additionally, in the subjectdescription, the word “exemplary” is used to mean serving as an example,instance or illustration. Any embodiment or design described herein as“exemplary” is not necessarily to be construed as preferred oradvantageous over other embodiments or designs. Rather, use of the wordexemplary is intended to present concepts in a concrete manner.Accordingly, all such modifications are intended to be included withinthe scope of the present inventions. The order or sequence of anyprocess or method steps may be varied or re-sequenced according toalternative embodiments. Any means-plus-function clause is intended tocover the structures described herein as performing the recited functionand not only structural equivalents but also equivalent structures.Other substitutions, modifications, changes, and omissions may be madein the design, operating conditions, and arrangement of the preferredand other exemplary embodiments without departing from scope of thepresent disclosure or from the spirit of the appended claims.

The present disclosure contemplates methods, systems and programproducts on any machine-readable media for accomplishing variousoperations. The embodiments of the present disclosure may be implementedusing existing computer processors, or by a special purpose computerprocessor for an appropriate system, incorporated for this or anotherpurpose, or by a hardwired system. Embodiments within the scope of thepresent disclosure include program products comprising machine-readablemedia for carrying or having machine-executable instructions or datastructures stored thereon. Such machine-readable media can be anyavailable media that can be accessed by a general purpose or specialpurpose computer or other machine with a processor. By way of example,such machine-readable media can comprise RAM, ROM, EPROM, EEPROM, CD-ROMor other optical disk storage, magnetic disk storage or other magneticstorage devices, or any other medium which can be used to carry or storedesired program code in the form of machine-executable instructions ordata structures and which can be accessed by a general purpose orspecial purpose computer or other machine with a processor. Wheninformation is transferred or provided over a network or anothercommunications connection (either hardwired, wireless, or a combinationof hardwired or wireless) to a machine, the machine properly views theconnection as a machine-readable medium. Thus, any such connection isproperly termed a machine-readable medium. Combinations of the above arealso included within the scope of machine-readable media.Machine-executable instructions include, for example, instructions anddata which cause a general purpose computer, special purpose computer,or special purpose processing machines to perform a certain function orgroup of functions.

Although the figures may show a specific order of method steps, theorder of the steps may differ from what is depicted. Also two or moresteps may be performed concurrently or with partial concurrence. Suchvariation will depend on the software and hardware systems chosen and ondesigner choice. All such variations are within the scope of thedisclosure. Likewise, software implementations could be accomplishedwith standard programming techniques with rule based logic and otherlogic to accomplish the various connection steps, processing steps,comparison steps and decision steps.

What is claimed is:
 1. A method of manufacturing a turbine blade,comprising: providing a core element including a base portion, a tipportion, and an intermediate portion extending between the base portionand the tip portion, the intermediate portion having a non-uniform crosssection and comprising a fiber material; surrounding the core elementwith a shell, a volume between the core element and the shell forming avoid; positioning a structural element within the void, wherein the coreelement comprises a plurality of individual fibers, at least one of theplurality of individual fibers peeling off of the core element to formthe structural element; and engaging the core element and the shell withthe structural element.
 2. The method of claim 1, wherein the coreelement defines an outer surface extending along the intermediateportion.
 3. The method of claim 2, wherein the shell includes an outersurface, an inner surface, and a wall, the inner surface and the outersurface disposed on opposite sides of the wall.
 4. The method of claim3, wherein the structural element extends from the outer surface of thecore element to the inner surface of the shell.
 5. The method of claim1, further comprising constructing the core element from a firstmaterial.
 6. The method of claim 5, wherein the first material isnon-metallic.
 7. The method of claim 6, wherein the core elementcomprises a plurality of individual fibers.
 8. The method of claim 5,further comprising constructing the shell from a second material.
 9. Themethod of claim 8, wherein the first material is non-metallic.
 10. Themethod of claim 9, wherein the core element comprises a plurality ofindividual fibers.
 11. The method of claim 8, wherein the secondmaterial is non-metallic.
 12. The method of claim 8, wherein the secondmaterial is different than the first material.
 13. The method of claim8, wherein the second material is metallic.
 14. The method of claim 1,further comprising providing a base member.
 15. The method of claim 14,further comprising coupling the shell to the base member.
 16. The methodof claim 15, further comprising insulating the core element from a hightemperature operating environment with the shell.
 17. The method ofclaim 1, further comprising coupling the shell to the base portion ofthe core element.
 18. The method of claim 17, further comprisingcoupling the shell to the tip portion of the core element.
 19. Themethod of claim 1, wherein the shell includes an intake side and anexhaust side.
 20. The method of claim 19, further comprising extendingthe structural element from the core element toward the intake side ofthe shell.
 21. The method of claim 19, further comprising extending thestructural element from the core element toward the exhaust side of theshell.
 22. The method of claim 1, further comprising extending a coolingelement through the void, the cooling element configured to increase amaximum operating temperature at the turbine blade.
 23. The method ofclaim 22, further comprising providing a fluid within the coolingelement.
 24. The method of claim 23, further comprising transferringenergy from the turbine blade with the fluid.
 25. The method of claim23, further comprising transferring energy from the shell to the coreelement with the fluid.
 26. The method of claim 23, further comprisingtransferring energy from the shell with the fluid.
 27. The method ofclaim 22, wherein the cooling element includes a plurality of heat sinksextending into the void from the shell.
 28. The method of claim 27,wherein the shell includes an outer surface, an inner surface, and awall, the inner surface and the outer surface disposed on opposite sidesof the wall.
 29. The method of claim 2, further comprising couplingfirst ends of the plurality of heat sinks to the inner surface.
 30. Themethod of claim 29, wherein second ends of the plurality of heat sinkscomprise free ends configured to move relative to the first ends. 31.The method of claim 29, further comprising coupling second ends of theplurality of heat sinks to the core element.